Communications cables having enhanced air space and methods for making same

Abstract

A communications cable is described. The communications cable can include a cable jacket, a separator structure that defines one or more channels for receiving at least one communications medium, and an insulator that surrounds the communications medium. The cable jacket can include one or more corrugations on at least one of its interior or exterior surfaces. The separator can also include one or more grooves on at least a portion of its surface. The insulator can also include one or more indentations on at least one of its interior or exterior surfaces. The corrugations, grooves, and indentations can extend along the longitudinal length of the cable and define one or more air channels for forwarding and circulating air through or on the surface the cable. The circulation of air in the cable can reduce the temperature of the cable and increase the quality of the signal transmitted through the cable.

What is claimed is: 
     
       1. A communications cable comprising:
 at least one transmission medium; 
 a support separator that defines at least one channel for receiving said transmission medium; and 
 a cable jacket that surrounds the support separator and the transmission medium, the cable jacket including an internal surface having a plurality of corrugations providing a plurality of air channels, and 
 wherein each corrugation has a height that is selected such that the cable jacket has a minimum thickness ranging from 0.010 inches to 0.013 inches, 
 wherein the support separator comprises a central region and a plurality of arms that extend from the central region, the plurality of arms defining said at least one channel for receiving the transmission medium, 
 wherein at least one of the plurality of arms comprises a generally T-shaped configuration, the generally T-shaped configuration formed by a first elongated portion extending out of the central region and a second portion connected to the first elongated portion, and 
 wherein at least one air channel of the plurality of air channels extends between the second portion and the cable jacket. 
 
     
     
       2. The communications cable of  claim 1 , wherein a minimum average thickness of the cable jacket ranges from 0.010 inches to 0.008 inches. 
     
     
       3. The communications cable of  claim 1 , wherein the plurality of corrugations are spaced evenly on said internal surface of the cable jacket. 
     
     
       4. The communications cable of  claim 1 , wherein the support separator comprises one or more grooves disposed along a surface thereof in said at least one channel. 
     
     
       5. The communications cable of  claim 4 , wherein a depth of at least one of the grooves ranges from 0.001 inches to 0.005 inches. 
     
     
       6. The communications cable of  claim 1 , wherein the support separator comprises a generally cross shape defining four symmetric quadrants, each quadrant defining a channel configured to receive the at least one transmission medium. 
     
     
       7. The communications cable of  claim 1 , wherein the support separator comprises a plurality of anvil-shaped arms that define two or more regions, each anvil being connected to at least one other anvil and each region including a channel configured to receive the at least one transmission cable. 
     
     
       8. The communications cable of  claim 7 , wherein at least two of the two or more regions are symmetric regions. 
     
     
       9. The communications cable of  claim 7 , wherein at least two of the two or more regions are asymmetric regions. 
     
     
       10. The communications cable of  claim 1 , wherein the support separator has a circumference ranging between 0.100 and 0.700 inches. 
     
     
       11. The communications cable of  claim 1 , wherein the plurality of corrugations comprise at least one of a tooth-shaped structure, a step-shaped structure, a zig-zag shaped structure, a turret-shaped structure, a structure including one or more castellation, or a combination thereof. 
     
     
       12. The communications cable of  claim 1 , further including an electrically insulating material that surrounds said at least one transmission medium, the insulating material having an interior surface comprising a plurality of indentations that define at least one air channel in proximity of said transmission medium. 
     
     
       13. The communications cable of  claim 12 , wherein each indentation comprises a height selected such that the insulating material has a minimum thickness ranging from 0.006 inches to 0.10 inches. 
     
     
       14. The communications cable of  claim 1 , wherein said at least one transmission medium comprises an electrically conductive wire. 
     
     
       15. The communications cable of  claim 1 , wherein said at least one transmission medium comprises an optical fiber. 
     
     
       16. The communications cable of  claim 1 , wherein at least one of the jacket or the support separator comprises any of a polyolefin, a polyurethane, a polyethylene, a polypropylene, fluorinated ethylene propylene, perfluoroalkoxy alkane, perfluoroalkoxy polymer, engineered resin, or combination thereof. 
     
     
       17. The communication cable of  claim 1 , wherein at least one of the support separator and the cable jacket is formed from a foamed polymeric material. 
     
     
       18. The communication cable of  claim 17 , wherein the foamed polymeric material is polyether ether ketone. 
     
     
       19. The communication cable of  claim 12 , wherein at least one of the support separator, the cable jacket and the electrically insulating material is formed from a foamed polymeric material. 
     
     
       20. A method for constructing a communications cable including one or more transmission media, a support separator that defines one or more channels for receiving the transmission media, and a jacket surrounding the transmission media and the support separator, the method comprising:
 forming a plurality of corrugations on an interior surface of the jacket, each of the plurality of corrugations having a height selected such that the cable jacket has a minimum thickness ranging from 0.010 inches to 0.013 inches and the plurality of corrugations defining a plurality of air channels for directing air through the communications cable, 
 wherein the support separator comprises a central region and a plurality of arms that extend from the central region, the plurality of arms defining said at least one channel for receiving the transmission medium, 
 wherein at least one of the plurality of arms comprises a generally T-shaped configuration, the generally T-shaped configuration formed by a first elongated portion extending out of the central region and a second portion connected to the first elongated portion, and 
 wherein at least one air channel of the plurality of air channels extends between the second portion and the cable jacket.